System and method for distributing vials to downstream locations in an automated pharmacy

ABSTRACT

An automated method and system for distributing vials to downstream locations in an automated pharmacy. More specifically, the present invention is a conveyor table having two U-shaped configurations for moving vials in a loop until the vials enter an open outbound lane. A barrier portion on the table guides vials from the conveyor table on an outbound lane for transport to a downstream location, such as a packing station. The outbound lane is operationally connected to a lane of stations, and the system is adapted to guide the vials to the first station that is open.

BACKGROUND

The present invention is directed to the field of automated dispensingsystems, more particularly to the transport of objects such as pharmacybottles/vials through an automated dispensing system. The presentinvention relates to an automated method and system for distributingvials to downstream locations in an automated pharmacy. Morespecifically, the present invention is a conveyor table having twoU-shaped conveyors for moving vials in a loop until they hit an openoutbound lane. A barrier portion on the table guides vials from theconveyor table to an outbound lane for transport to a downstreamlocation, such as a packing station. The outbound lane is operationallyconnected to a lane of stations, and the system is adapted to guide thevials to the first station that is open.

Many health benefit plan providers and retail pharmacies offer theirclients the option of obtaining prescription drugs by mail. Mail orderpharmacies ship prescription drugs to a client's home so the client isnot required to visit a pharmacy to fill a prescription in person. Forclients with chronic conditions or other health conditions that requiremaintenance drugs, a mail order prescription program is an attractivebenefit because it is more convenient for the clients and typically lessexpensive than obtaining prescription drugs at a neighborhood pharmacy.Clients have the option of purchasing many widely-prescribed maintenancedrugs, for example, in a 60-day or even a 90-day supply at a lower costthan a 30-day supply.

Most mail order pharmacies use automated systems and dispensing lines toprocess and ship a high volume of prescriptions on a daily basis. Eachprescription medication is typically dispensed into a vial or othercontainer labeled with data from an electronic order that identifies thepatient, drug (e.g., by NDC), dosage, and quantity. Each medication isdispensed in its own vial and in many instances, multiple vials arecombined into a single package and shipped to a single address for aclient with one or more chronic conditions requiring multiplemedications. The automated dispensing system, therefore, must beintelligent and capable of determining which vials should be combinedinto a single package. The system must also be capable of routing thevials through the system to their appropriate destinations. Sensorsdeployed at many locations along the system detect the prescriptioninformation on the bottles along with RFID tag information tointelligently route and divert the vials to the appropriate conveyor ordestination. If the vial is to be combined with other vials (multi-vialorder), the vials are sorted and grouped together, preferably towardsthe end of the dispensing line. The vials are ultimately routed to thefinal location for packaging and mailing to the consumer.

Automated dispensing lines typically comprise multiple sorting stationsand therefore, require functionality to route and divert vials to theappropriate station. The process of routing and diverting vials forsorting and consolidation as well as other reasons can increase vialtravel and processing time.

Depending upon how the technology is implemented and deployed within amail order pharmacy, a substantial number of steps in the fulfillmentprocess may be automated and the need for human intervention minimized.Transporting bottles through the automated dispensing lines in anefficient, timely, accurate, and consistent manner is crucial forfilling the high volume of mail order prescriptions.

One technique for processing multi-prescription orders is to group thevials for the order and process them together so that all vials arrivefor packaging and shipping as a group. Although “group processing” ofvials is a logical approach to processing and packaging vials destinedfor a single address, it is not an efficient approach. Implementation of“group processing” on an automated dispensing line may requiredevelopment of sophisticated algorithms for determining a reasonable oradequate route for the vials to travel as well as holding or reorderingof other orders to permit the vials for a multi-prescription order totravel on the line as a group. The requirement for holding andreordering of orders increases vial processing time. In addition,processing of the vials in a group may require longer overall traveltimes for the vials as the vials are routed as a group and required tomake unnecessary stops at stations other than the one station that hasthe appropriate medication for the vial.

A more efficient approach to processing of multi-prescription ordersinvolves processing each vial of medication separately and then sortingand consolidating or regrouping them for packaging and shipping to asingle address. Single vial processing is typically more efficient thangroup vial processing and reduces the overall travel and processing timefor each vial. Single vial processing, however, requires the developmentof methods for tracking the vials during processing and eventually,sorting and consolidating them for packaging and shipping. Thesorting/consolidation process typically involves diverting vials of amulti-prescription order to a sorting station where vials are held untilall of the vials for an order have arrived. The vials are grouped at thestation and then released for packaging.

Processing times for vials on an automated dispensing line are impactedby various routing and diverting techniques that are employed tofacilitate single vial processing as well as multi-prescription orderprocessing. There is a need for an improved pharmaceutical vialprocessing system and method that reduces processing delays attributableto routing and diverting techniques.

Within a typical pharmacy production facility, there are automaticprocesses for the counting and sorting of pill tablets. For example,orders for vials of particular pills are processed automatically throughan integrated system of pill counters and conveyors for transporting thevials to the appropriate outbound conveyor location (e.g., or a sorterlocation). Typically, these facilities are configured with multipleoutbound conveyor lanes to allow for higher vial production volumes.

However, with this type of arrangement, multiple vials assigned to onespecific order might be distributed to different take away or outboundconveyors which presents problems with the desired goal of getting allof the vials to reach the same downstream order sorter location. When avial assigned to an order does not reach the designated order sorterlocation at approximately the same time as the other vials in the sameorder, the release of that order will be delayed, slowing order sorterthroughput and diminishing overall productivity of the system.

Additional complications can also arise because demand for differentdrugs constantly changes which can result in high vial numbers occupyingan inbound lane. To cope with these high vial numbers, the controlsystem in typical conveyor systems would have to transfer vials acrossconveyor lanes up to three times or more to keep both the load balancedon the inbound lane and get the vials to their correct order sorterlocation. These systems were set up as single-file conveyor lanesthroughout a majority of the system. Such a system requires complexcontrol systems, sensors, and a large number of diverter devices fordiverting vials from one conveyor onto another. The need for suchcomplex control systems having a large number of hardware componentsdecreases the speed of the automated systems, increases the cost of thesystems, and increases the probability that the system will malfunctionor break down.

Product conveyor and accumulation systems are previously known. Forexample, U.S. Pat. Nos. 6,575,287 and 6,648,124, describe productconveying and accumulation systems for transporting products from anupstream to downstream location. These systems are comprised of multipleconveyors positioned next to each other to move objects from one end ofthe conveyor to the other end. These systems can also be used with guiderails and object guides to move objects to desired locations or outboundchannels. If these outbound channels are full or backed up, the objectsare allowed to circulate around the conveyor system until a channelbecomes free.

The present invention relates to a new type of automated pharmacyprescription fulfillment system using specifically configured mass flowconveyor tables at predetermined points in the system to route vials todesired destinations within the automated pharmacy system. These massflow conveyor tables allow vials to move along the conveyors systems ina mass flow rather than a single-file line. These mass flow tableseliminate the need for complex control systems, reduce the need for manydiversion mechanisms for diverting vials off single-file conveyor lanes,and reduces the need for many sensors for sensing and balancing vialloads on single-lane conveyors. For example, use of mass flow conveyortables at certain predetermined points of the automated pharmacy systemcan be used to accumulate vials and/or to distribute them to outboundconveyor lanes automatically as these outbound lanes become available(or open up). These mass flow conveyor tables can also be configured toprovide overflow lanes in case the primary lanes back up.

The present system uses specifically configured mass flow vial conveyorsystems at predetermined locations of the automated pharmacy line tofill prescriptions orders in a more effective, faster, and efficient waythan traditional conveyor systems using single-file conveyor lines.

SUMMARY OF THE GENERAL INVENTIVE CONCEPT

In one embodiment of the invention, the invention is comprised of: afirst conveyor portion configured in a U-shape configuration, whereinthe first conveyor portion is comprised of a curved portion, a firstside portion, and a second side portion; a second conveyor portionconfigured in a U-shape configuration, wherein the second conveyorportion is comprised of a curved portion, a first side portion and asecond side portion; wherein the curved portion of the first conveyorportion is at the opposite end of the table from the curved portion ofthe second conveyor portion; wherein the first side portion of the firstconveyor portion runs parallel to, and in the same direction as, thefirst side portion of the second conveyor portion; wherein the secondside portion of the first conveyor portion runs parallel to, and in thesame direction as, the second side portion of the second conveyorportion; a first inbound conveyor lane positioned to transport vialsonto the conveyor table; a first outbound conveyor lane positioned totransport vials from the conveyor table to a first downstreamdestination; a first barrier portion positioned on the conveyor tablefor guiding vials from the conveyor table onto the first outbound lane;and wherein the conveyor table is configured to transport vials aroundthe table and wherein vials entering the table from the first inboundconveyor lane hit the first barrier portion and wherein the firstbarrier portion is adapted to guide vials onto the first outboundconveyor lane if it is open and wherein the vials move onto the firstside portion of the second conveyor portion if the first outboundconveyor lane is full or closed, and wherein the conveyor table isadapted to move vials from the first side portion of the second conveyorportion to the second side portion of the second conveyor portion.

The foregoing and other features and advantages of the present inventionwill be apparent from the following more detailed description of theparticular embodiments, as illustrated in the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In addition to the features mentioned above, other aspects of thepresent invention will be readily apparent from the followingdescriptions of the drawings and exemplary embodiments, wherein likereference numerals across the several views refer to identical orequivalent features, and wherein:

FIG. 1 illustrates a top plan view of one embodiment of the conveyordistribution table for distributing vials to the single-vial packingstations;

FIG. 2 illustrates rows of packing stations connected to outbound lanesof the conveyor distribution table.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

The following detailed description of the exemplary embodiments refersto the accompanying figures that form a part thereof. The detaileddescription provides explanations by way of exemplary embodiments. It isto be understood that other embodiments may be used having mechanicaland electrical changes that incorporate the scope of the presentinvention without departing from the spirit of the invention.

The present invention relates to a mass flow vial conveyor system foraccumulating and/or distributing vials for prescription fulfillment.Mass flow conveyor systems or tables at various locations in thepharmacy line move bottles/vials in mass quantities as opposed to asingle-file, dedicated, conveyor line process used at traditionalautomated pharmacy fulfillment systems. Use of these mass flow conveyorsystems increases speed and increases reliability of the pharmacy lineby reducing the number of controls needed for a single-file typepharmacy line. For example, in the present system, a mass flow vialconveyor system may be used for distributing the single-vialprescription orders to packing stations (the mass flow table moves thevials around and distributes the vials to available packing stations forpacking and then mailing to customers). In the preferred embodiment,each outbound lane of the mass flow table feeds a packing station withoverflow lanes available if all of the packing stations are at fullcapacity.

After vials have been filled and capped, vials are transported byconveyors to a packing station where the vials are packaged for mailingto consumers. In one embodiment, there are two separate packing areas,one for single-vial orders and another for multi-vial orders aspreviously discussed. In the present invention, a mass flow vialconveyor system distributes the single-vial prescription orders topacking stations. Its function is to feed single vial orders to thepacking stations in a cascading/waterfall fashion.

FIG. 1 illustrates one embodiment of the conveyor distribution table fordistributing vials to the single-vial packing stations (top diagramview). In this embodiment, vials enter the table from two inbound lanes139, 140 from an upstream location. The vials move around the conveyortable to a first conveyor portion 141 of the table and enter the firstoutbound conveyor lane 142 if it is open (not full of vials or blocked).If the first outbound lane is not open, the vials will circulate to asecond conveyor portion 143 of the table and enter a second outboundconveyor lane 144 if it is open. As previously discussed, thedistribution table is adapted with barriers or guides 146, 147 thatguide the vials from the table to the outbound conveyor lanes. There areopenings in the barrier/guide that lead to the outbound conveyor lanes.When these openings are not open, the vials cannot enter the opening andtherefore the vials keep circulating around the table until an outboundlane opens up.

The barriers or guides are preferably pieces of hard white plastic—e.g.,ultra-high molecular weight (UHMW) polyethylene barriers or guideportions—placed on the table. These plastic pieces are shaped in such away as to direct or guide puck flow into the first outbound lane that isnot full. In essence, the methodology relies on physics. If enough puckshave gathered in the first outbound lane, for instance, then the shapeof the UHMW guide portion will flow the pucks down the moving conveyorto the next outbound lane, e.g., analogous to the movement of acascading waterfall. When one lane fills up, the pucks coming down thetable move down to the next open lane.

Pairing these plastic “arms” or barriers or guides with conveyormovement directs puck flow, eliminating the need for many PLC- andsoftware-operated controls (e.g., photo-electric sensors, diverts, puckstops, RFIDs). The UHMW plastic material is extremely durable, known forits ability to resist abrasion and impact. Because of these properties,UHMW's benefits include cutting down on maintenance costs and energyconsumption.

More specifically, in the embodiment of FIG. 1, the conveyor table iscomprised of a:

-   -   a. a first conveyor portion 141 that is configured in a U-shape        configuration, wherein the conveyor travels in the direction as        indicated by the arrows in FIG. 1, and wherein the first        conveyor portion is comprised of a curved portion 150, a first        side portion 152 and a second side portion 154;    -   b. the second conveyor portion 143 also configured in a U-shape        configuration, wherein the conveyor travels in the direction as        indicated by the arrows in FIG. 1, and wherein the second        conveyor portion is comprised of a curved portion 156, a first        side portion 158 and a second side portion 160;    -   c. wherein the curved portion of the first conveyor portion is        at the opposite end of the table from the curved portion of the        second conveyor portion;    -   d. wherein the first side portion of the first conveyor portion        runs parallel to, and in the same direction as, the first side        portion of the second conveyor portion;    -   e. wherein the second side portion of the first conveyor portion        runs parallel to, and in the same direction as, the second side        portion of the second conveyor portion;    -   f. a first inbound conveyor lane 139 positioned to transport        vials onto the conveyor table (e.g., onto the first side portion        of the first conveyor portion);    -   g. a first outbound conveyor lane 142 positioned to transport        vials from the conveyor table to a first downstream destination;    -   h. a first barrier portion 146 positioned on the conveyor table        for guiding vials from the conveyor table onto the first        outbound lane;    -   i. a second outbound conveyor lane 144 positioned to transport        vials from the conveyor table to a second downstream        destination;    -   j. a second barrier portion 147 positioned on the conveyor table        for guiding vials from the table onto the second outbound lane;    -   k. a second inbound conveyor lane 140 positioned to transport        vials onto the conveyor table (e.g., the curved portion of the        first conveyor portion);    -   l. wherein the conveyor table is configured to transport vials        around the table and wherein vials entering the table from the        first inbound conveyor lane hit the first barrier portion and        wherein the first barrier portion is adapted to guide vials onto        the first outbound conveyor lane if it is open and wherein the        vials move onto the first side portion of the second conveyor        portion if the first outbound conveyor lane is full or closed,        and wherein the conveyor table is adapted to move vials from the        first side portion of the second conveyor portion to the second        side portion of the second conveyor portion;    -   m. wherein the conveyor is adapted to transport vials on the        second side portion of the second conveyor portion to the second        barrier portion and wherein the second barrier portion is        adapted to guide vials into the second outbound conveyor lane if        it is open and wherein the vials move onto the second side        portion of the first conveyor portion if the second outbound        conveyor lane is full or closed;    -   n. a first intervening conveyor portion positioned between the        first side portions of the first and second conveyor portions;    -   o. a second intervening conveyor portion positioned between the        second side portions of the first and second conveyor portions.

The first and second outbound conveyor lanes 142, 144 each lead to aplurality of packing stations, respectively. For example, FIG. 2illustrates an embodiment where each outbound lane leads to rows ofpacking stations 165. The vials will automatically go into a packingstation that is open (via guides that guide the vial into a conveyorlane leading to the packing station). If the packing station lane isfull (backed-up), the vial will move on to the next station, and so onand so forth, and enter the next station that is open (e.g., a waterfalleffect on the table). In other words, the packing stations areconfigured in a stacked configuration so that vials will go into thefirst packing station that is open and wherein the vials will move pastfull packing stations. Gates may be placed at the entrance to a packingstation if it is desired to close down a particular packing station formaintenance, work flow, load or other reasons.

In another embodiment of the conveyor table of FIG. 1, there is only oneinbound conveyor lane and one outbound conveyor lane. In such a system,the conveyor table is adapted to move the vials around the first andsecond conveyor portions in a loop pattern until the first barrierguides the vials onto the first outbound lane.

While certain embodiments of the present invention are described indetail above, the scope of the invention is not to be considered limitedby such disclosure, and modifications are possible without departingfrom the spirit of the invention as evidenced by the following claims.

What is claimed is:
 1. A vial conveying and distributing system fordistributing vials, comprising: a conveyor table comprised of: a firstconveyor portion configured in a U-shape configuration, wherein thefirst conveyor portion is comprised of a curved portion, a first sideportion, and a second side portion; a second conveyor portion configuredin a U-shape configuration, wherein the second conveyor portion iscomprised of a curved portion, a first side portion and a second sideportion; wherein the curved portion of the first conveyor portion is atthe opposite end of the table from the curved portion of the secondconveyor portion; wherein the first side portion of the first conveyorportion runs parallel to, and in the same direction as, the first sideportion of the second conveyor portion; wherein the second side portionof the first conveyor portion runs parallel to, and in the samedirection as, the second side portion of the second conveyor portion; afirst inbound conveyor lane positioned to transport vials onto theconveyor table; a first outbound conveyor lane positioned to transportvials from the conveyor table to a first downstream destination; a firstbarrier portion positioned on the conveyor table for guiding vials fromthe conveyor table onto the first outbound lane; a second outboundconveyor lane positioned to transport vials from the conveyor table to asecond downstream destination; and wherein the conveyor table isconfigured to transport vials around the table and wherein vialsentering the table from the first inbound conveyor lane hit the firstbarrier portion and wherein the first barrier portion is adapted toguide vials onto the first outbound conveyor lane if it is open andwherein the vials move onto the first side portion of the secondconveyor portion if the first outbound conveyor lane is not open, andwherein the conveyor table is adapted to move vials from the first sideportion of the second conveyor portion to the second side portion of thesecond conveyor portion.
 2. The system of claim 1, wherein the firstinbound lane is positioned to transport vials onto the first sideportion of the first conveyor portion.
 3. The system of claim 1, furthercomprising a second inbound conveyor lane positioned to transport vialsonto the conveyor table.
 4. The system of claim 1, wherein the conveyortable is adapted to move vials around the first and second conveyorportions in a loop pattern until the first barrier portion guides thevials onto the first outbound lane.
 5. The system of claim 1, furthercomprising: a first intervening conveyor portion positioned between thefirst side portions of the first and second conveyor portions.
 6. Thesystem of claim 5, further comprising: a second intervening conveyorportion positioned between the second side portions of the first andsecond conveyor portions.
 7. The system of claim 1, further comprising:a first lane of packing stations operationally connected to the firstoutbound conveyor lane, wherein the system is adapted so that vials willgo into the first packing station that is open.
 8. The system of claim7, wherein the first lane of packing stations is configured in a stackedconfiguration so that vials will go into the first packing station thatis open and wherein the vials will move past packing stations that arenot open.
 9. The system of claim 8, further comprising: a plurality ofgates placed at the entrances of each of the packing stations forblocking entry into the packing stations when the gates are closed. 10.The system of claim 1, further comprising: a second barrier portionpositioned on the conveyor table for guiding vials from the table ontothe second outbound conveyor lane.
 11. The system of claim 10, whereinthe second conveyor portion is adapted to transport vials on the secondside portion of the second conveyor portion to the second barrierportion and wherein the second barrier portion is adapted to guide vialsinto the second outbound conveyor lane if it is open and wherein thevials move onto the second side portion of the first conveyor portion ifthe second outbound conveyor lane is not open.
 12. The system of claim11, further comprising a second inbound conveyor lane positioned totransport vials onto the conveyor table.
 13. The system of claim 11,further comprising: a second lane of packing stations operationallyconnected to the second outbound conveyor lane, wherein the system isadapted so that vials will go into the first packing station that isopen.
 14. A vial conveying and distributing system for distributingvials, comprising: a conveyor table comprised of: a first conveyorportion configured in a U-shape configuration, wherein the firstconveyor portion is comprised of a curved portion, a first side portion,and a second side portion; a second conveyor portion configured in aU-shape configuration, wherein the second conveyor portion is comprisedof a curved portion, a first side portion and a second side portion;wherein the curved portion of the first conveyor portion is at theopposite end of the table from the curved portion of the second conveyorportion; wherein the first side portion of the first conveyor portionruns parallel to, and in the same direction as, the first side portionof the second conveyor portion; wherein the second side portion of thefirst conveyor portion runs parallel to, and in the same direction as,the second side portion of the second conveyor portion; a first inboundconveyor lane positioned to transport vials onto the conveyor table; afirst outbound conveyor lane positioned to transport vials from theconveyor table to a first downstream destination; a first barrierportion positioned on the conveyor table for guiding vials from theconveyor table onto the first outbound lane; a second outbound conveyorlane positioned to transport vials from the conveyor table to a seconddownstream destination; and wherein the conveyor table is configured totransport vials around the table and wherein vials entering the tablefrom the first inbound conveyor lane hit the first barrier portion andwherein the first barrier portion is adapted to guide vials onto thefirst outbound conveyor lane if it is open and wherein the vials moveonto the first side portion of the second conveyor portion if the firstoutbound conveyor lane is not open, and wherein the conveyor table isadapted to move vials from the first side portion of the second conveyorportion to the second side portion of the second conveyor portion; and afirst lane of packing stations operationally connected to the firstoutbound conveyor lane, wherein the system is adapted so that vials willgo into the first packing station that is open.
 15. The system of claim14, wherein the first lane of packing stations is configured in astacked configuration so that vials will go into the first packingstation that is open and wherein the vials will move past packingstations that are not open.
 16. The system of claim 14, furthercomprising: a plurality of gates placed at the entrances of each of thepacking stations for blocking entry into the packing stations when thegates are closed.
 17. A vial conveying and distributing system fordistributing vials, comprising: a conveyor table comprised of: a firstconveyor portion; a second conveyor portion operationally connected tothe first conveyor portion; a first inbound conveyor lane positioned totransport vials onto the conveyor table; a first outbound conveyor lanepositioned to transport vials from the conveyor table to a firstdownstream destination; a first barrier portion positioned on theconveyor table for guiding vials from the conveyor table onto the firstoutbound lane; a second outbound conveyor lane positioned to transportvials from the conveyor table to a second downstream destination;wherein the conveyor table is configured to transport vials around thetable and wherein vials entering the table from the first inboundconveyor lane hit the first barrier portion and wherein the firstbarrier portion is adapted to guide vials onto the first outboundconveyor lane if it is open and wherein the vials move onto the secondconveyor portion if the first outbound conveyor lane is not open. 18.The system of claim 17, further comprising a second inbound conveyorlane positioned to transport vials onto the conveyor table.
 19. Thesystem of claim 17, wherein the conveyor table is adapted to move vialsaround the first and second conveyor portions in a loop pattern untilthe first barrier portion guides the vials onto the first outbound lane.20. The system of claim 17, further comprising: a second barrier portionpositioned on the conveyor table for guiding vials from the table ontothe second outbound conveyor lane.
 21. The system of claim 20, whereinthe system is adapted to transport vials on the second conveyor portionto the second barrier portion and wherein the second barrier portion isadapted to guide vials into the second outbound conveyor lane if it isopen and wherein the vials move onto the first conveyor portion if thesecond outbound conveyor lane is not open.
 22. The system of claim 17,further comprising: a first lane of packing stations operationallyconnected to the first outbound conveyor lane, wherein the system isadapted so that vials will go into the first packing station that isopen.
 23. The system of claim 22, wherein the first lane of packingstations is configured in a stacked configuration so that vials will gointo the first packing station that is open and wherein the vials willmove past packing stations that are not open.